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Rockwell Automation Publication 7712-UM001D-EN-P - October 2017

45

Maintenance

Chapter 5

Contactor Cart Maintenance

Replace the Vacuum Bottles

Under normal conditions, vacuum bottles will last at least 1,000,000

operations; however, all three bottles must be replaced if any wear indicator

line (

Figure 24

) reaches the bearing (regardless of the number of operations).

Figure 24 - Vacuum bottle wear indicator

To access the vacuum bottles, the glastic cover must be removed. See page

1. Unscrew eleven M8 bolts to remove the fuse mounting mold

(

Figure 25

).

Figure 25 - Remove Fuse Mounting Mold

Vacuum Bottle

Wear indicator line
on operating shaft

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Содержание Allen-Bradley 7712

Страница 1: ...OneGear 7 2 kV Motor Controller Full voltage Non reversing Bulletin Number 7712 User Manual OriginalInstructions ...

Страница 2: ...information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations Labels may also be on or inside the equipment to provide specific precautions WARNING Identifies informati...

Страница 3: ...d Accessibility Requirements Recommended Torque Values 15 Open the Enclosure Doors 16 Opening the Low Voltage Door 16 Opening the Medium Voltage Door 17 Chapter3 Start up Procedure Contactor Inspection 19 Preliminary Checks 19 Testing Contactor Operation 20 Test Power Supply 21 Operating Position 21 Chapter4 Equipment Operation Power Lockout Procedure 27 Open Contactor 27 Power Down Low Voltage Se...

Страница 4: ... 53 Inspect and Lubricate Earthing Switch Mechanism 53 Ground Connection Inspection 55 Toggle Assembly Inspection 55 Earthing Switch Auxiliary Maintenance 56 Auxiliary Contacts Replacement 56 Auxiliary Contacts Adjustment 56 Earthing Switch Auxiliary Contacts Inspection 57 AppendixA Spare Parts Typical Bulletin 7712 Parts 59 AppendixB Certification Data Test Summary 61 High Voltage Controlgear Sta...

Страница 5: ...ontents Connections 70 Motor Connection from 7791 70 Motor Connection from 7712 70 Interlock Operation Sequence One Motor 70 Initial Condition 70 To Run Drive 70 To Run Bypass 71 To open Drive for Service 71 To open Output Cabinet 71 Interlock Operation Sequence Two Motors 71 ...

Страница 6: ...6 Rockwell Automation Publication 7712 UM001D EN P October 2017 Table of Contents Notes ...

Страница 7: ...ethod of servicing medium voltage products Contact your local area support office to make arrangements to have a qualified service representative come to your facility A complete listing of Area Support Offices may be obtained by calling your local Rockwell Automation Distributor or Sales Office For Medium Voltage technical support on start up or existing installations contact your Rockwell Automa...

Страница 8: ...tches European Directives for Safety and EMC RoHS Note It is the responsibility of the customer and or installer to know and meet all local codes standards and OSHA requirements Controller Unit Identification A nameplate is attached to the front door of the structure see Figure 1 Refer to the nameplate for information such as series number section number enclosure type unit ratings and bus ratings...

Страница 9: ...ifications and an overview of the features andfunctions provided by the controller and in coming line unit OneGearSMCFlexSolid StateMotorController 10 15 kV Specification Guide 7760 SR001 Provides a outline for the overall fabrication performanceandfunctionalrequirementsforamedium voltage reduced voltage solid state motor controller RVSS for use with induction and brush type synchronous motors How...

Страница 10: ...10 Rockwell Automation Publication 7712 UM001D EN P October 2017 Preface Notes ...

Страница 11: ...tance The controller must be derated for ambient temperatures above 40 ºC 104 F The equipment operates at altitudes from 0 1000 m 3300 ft above sea level without de rating For applications above 1000 m 3300 ft the maximum current and Basic Impulse Levels B I L of the controllers and incoming line unit shall be de rated and vacuum contactors breakers will be compensated for operation at the specifi...

Страница 12: ... Height 1 1 The height dimension does not include the plenum 574 mm 22 60 in which is removed for shipping and installed by the customer The total height of the unit including an installed plenum is 2674 mm 105 27 in Depth Weight 7712 250 A single fuse FVNR Controller 350 mm 13 78 in 2200 mm 86 71 in 1100 mm 43 31 in 489 kg 1075 lb 7712 330 A double fuse FVNR Controller 350 mm 13 78 in 2200 mm 86 ...

Страница 13: ...ucture All covers plates and hardware removed for installation or maintenance purposes must be re installed and properly secured Failure to do so voids the arc flash resistant integrity Power cable entry points are to be treated as the boundary between a hazardouslocationandsealedaccordingly Failuretodosovoidsthearcflash resistant integrity A plenum must be used to direct the arc flash energy to a...

Страница 14: ...14 Rockwell Automation Publication 7712 UM001D EN P October 2017 Chapter 1 General Information Notes ...

Страница 15: ...may result in severe burns injury or death IMPORTANT For general information on handling medium voltage controllers and preparing the installation site see publication MV QS050 ATTENTION Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death Hardware Size Tightening Torque Required 1 4 in M6 6 ft lb 8 N m 5 16 in M8...

Страница 16: ...sing an Allen key turn the two 1 4 turn fasteners 90 clockwise and swing the door to the left Close and secure the low voltage door in the reverse order of opening Figure 4 Enclosure Compartments IMPORTANT The medium voltage door is interlocked to the isolation shutter and or the earthing switch The low voltage panel compartment and power cell are separated by an isolation barrier ArecShield Plenu...

Страница 17: ... of opening ATTENTION This procedure requires contact with medium voltage components To avoid shock hazards complete the Power Lockout procedure on page 27 before servicing the equipment Verify with a hot stick or appropriatevoltagemeasuringdevicethatallcircuitsarevoltagefree Failure to do so may result in severe burns injury or death IMPORTANT Failure to open the medium voltage door in the proper...

Страница 18: ...18 Rockwell Automation Publication 7712 UM001D EN P October 2017 Chapter 2 Safety Interlock and Accessibility Requirements Notes ...

Страница 19: ...orrect Heater elements if provided in the overload relay are secure and undamaged All equipment is correctly grounded External power and control connections match the electrical diagrams All hardware is correctly reinstalled and torqued to the correct specification see Recommended Torque Values on page 15 All barriers are replaced and in the correct position All fuses are the correct class type an...

Страница 20: ...h is closed The shutter behind the cart in the MV compartment should be closed under this situation This should be confirmed after opening the MV door If the MV door cannot be opened smoothly the shutter is not completely shut off or the earthing switch is not completely closed ATTENTION Always perform the power lockout procedure before servicing equipment Failure to do so may result in severe bur...

Страница 21: ...ctions of this equipment Any operation on the contactor will affect the MV status on the load side ATTENTION Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death IMPORTANT It is not possible to use any test power supply after the contactor cart has been racked out of the test position A set of auxiliary switches o...

Страница 22: ...V panel as designed Test the Contactor Contactor must be in the withdrawn test position 1 Connect the appropriate external power supply 120V or 230V AC to the test receptacle in the control panel Turn the selector switch to the TEST position 2 Electrically operate the contactor several times Inspect the armature plate to verify that it fully contacts the magnetic cores Contactor should close when ...

Страница 23: ...Rockwell Automation Publication 7712 UM001D EN P October 2017 23 Start up Procedure Chapter 3 Figure 6 TypicalWiringDiagram Electrically Held Vacuum Contactor with IntelliVAC Control ...

Страница 24: ...24 Rockwell Automation Publication 7712 UM001D EN P October 2017 Chapter 3 Start up Procedure ...

Страница 25: ...Rockwell Automation Publication 7712 UM001D EN P October 2017 25 Start up Procedure Chapter 3 ...

Страница 26: ...26 Rockwell Automation Publication 7712 UM001D EN P October 2017 Chapter 3 Start up Procedure ...

Страница 27: ...oller 2 Open low voltage door to check the contactor status LED of IntelliVAC it must be off Power Down Low Voltage Section Besides either customer supplied LV power or defaulted CPT mounted on the contactor cart the Low Voltage Section can also be powered by a temporary LV test power supply 1 Turn the selection switch to Off 2 Unplug the temporary test power supply 3 Disconnect any customer suppl...

Страница 28: ...itch to the Test position e Electrically operate the contactor by pushing the Start button on the unit or at a remote location f Disengage the contactor and turn the control switch to the Normal position Disconnect the external power supply g Complete the Power Lockout procedure 4 Use a 120V power cord and plug into the 120V plug on the Control Switch Assembly see Figure 5 on page 20 to test the s...

Страница 29: ...ush toward rear of cabinet The wrench must be pushed toward rear of cabinet to unlock the cart raking screw The pressure must be maintained for the entire cart insertion withdraw operation 4 If cart is in test withdrawn position rotate the speed wrench clockwise to insert the cart Figure 8 From test to service position requires 11 complete rotations a mechanism stops the screw rotation after 11 tu...

Страница 30: ...nfromthemechanismwithoutanyrotation This ensures the locking plate in the front of the cart will slide forward and lock the end of the racking screw locking in the same time the cart position The tool access flap must cover the opening after the speed wrench is redrawn IMPORTANT Before opening the earthing switch ensure the contactor cart is in the withdrawn test position and the door is closed an...

Страница 31: ...tely closed Earthing Switch Positioning Indicators An arrow at the end of the earthing switch shaft indicates the state of the switch Depending on the position of the earthing switch the arrow points to the corresponding decal located on the door Open ClosedPositionIndicatorDecal In the closed position Figure 11 the arrow points toward I red background Figure 11 Switch indicator Off Earthing switc...

Страница 32: ...the test withdrawn position The LV Plug and cable is attached on the cabinet door and is connected to the equipment in the LV cabinet on the top 1 Orient the LV plug aligning the guide pins on the cart with the openings in the plug 2 Push down the plug and secure the connection with the locking arm mounted on the cart Figure 13 Open position IMPORTANT LV must be connected for unit functionality Th...

Страница 33: ...osition The color of the indicator will change to red even if the shutter door is partially open Figure 14 Shutter position Indicator Green The shutter door is closed Figure 16 the cart is completely redrawn in the test position Red The shutter door is open Figure 17 the indicatorwill change immediately after moving the cart from test withdrawn position to the service position Close position Green...

Страница 34: ...2017 Chapter 4 Equipment Operation A viewing window Figure 15 shows the position of the contactor cart Figure 15 Viewing Window Figure 16 Shutter closed TIP Iftheshutterdoorispartiallyorfullyopen aninterlockpreventstheMVdoor from opening Viewing Window Indicator ...

Страница 35: ...Rockwell Automation Publication 7712 UM001D EN P October 2017 35 Equipment Operation Chapter 4 Figure 17 Shutter open ...

Страница 36: ...36 Rockwell Automation Publication 7712 UM001D EN P October 2017 Chapter 4 Equipment Operation Notes ...

Страница 37: ...S 1 3 Preventive Maintenance of Industrial Control and Systems Equipment for general guidelines for setting up a periodic maintenance program Some specific guidelines for Rockwell Automation products are listed below ATTENTION Servicing energized Industrial Control Equipment can be hazardous Severe injury or death can result from electrical shock bump or unintended actuation of controlled equipmen...

Страница 38: ...om sticking or binding Replace any broken deformed or badly wont parts or assemblies according to individual product renewal parts lists Check for and retighten securely any loose fasteners Lubricate if specified in individual product instructions Note Allen Bradley magnetic starters contactors and relays are designed to operate without lubrication do not lubricate these devices because oil or gre...

Страница 39: ... a soft dry cloth Reflective devices used in conjunction with photoelectric switches also require periodic cleaning Do not use solvents or cleaning agents on the lenses or reflectors Replace any damaged lenses and reflectors Annual Maintenance Requirements Task Page Remove Contactor Cart 40 Remove and Replace Fuses 43 Contactor Cart Maintenance 45 Replace the Vacuum Bottles 45 Calibrate the Overtr...

Страница 40: ... contactor cart platform is the same elevation as the service cart rails 2 Move the service cart to the cabinet and insert the cart pins into the enclosure Figure 18 Figure 18 Securing Service Cart to the front of the Cabinet 3 Insert cart latch key into the cart latch disengagement and turn the key approximately a quarter turn clockwise Figure 19 Ensure latch is disengaged from the rail ATTENTION...

Страница 41: ...4 Keeping the key engaged grasp the handle Figure 20 and remove the contactor cart from the enclosure onto the service cart Figure 20 Contactor Cart Removal Handle 5 Once the contactor cart is extracted from the cabinet secure the cart using the latch and the service cart wheels to prevent movement Disengage cart latch ...

Страница 42: ...42 Rockwell Automation Publication 7712 UM001D EN P October 2017 Chapter 5 Maintenance Figure 21 Contactor Cart removed from enclosure ...

Страница 43: ...well Automation Publication 7712 UM001D EN P October 2017 43 Maintenance Chapter 5 Remove and Replace Fuses 1 Unscrew eight M8 bolts to remove the red Glastic cover Figure 22 Figure 22 Remove Glastic cover ...

Страница 44: ...tion Publication 7712 UM001D EN P October 2017 Chapter 5 Maintenance 2 Replace each fuse by removing four M10 nuts Figure 23 Figure 23 Fuse Removal 3 Replace the M10 nuts and reattach the Glastic cover using the M8 bolts ...

Страница 45: ...tions however all three bottles must be replaced if any wear indicator line Figure 24 reaches the bearing regardless of the number of operations Figure 24 Vacuum bottle wear indicator To access the vacuum bottles the glastic cover must be removed See page 43 1 Unscrew eleven M8 bolts to remove the fuse mounting mold Figure 25 Figure 25 Remove Fuse Mounting Mold Vacuum Bottle Wear indicator line on...

Страница 46: ...Figure 26 Remove lower terminal connections 3 Remove the load terminal retaining bolt at the rear of the contactor and the vacuum bottle mounting bolt at the top of the contactor Figure 27 Figure 27 Mounting and Retaining bolt removal TIP Before removing the vacuum bottles mark the installed bottles clearly to avoid confusing them with the replacement vacuum bottles ...

Страница 47: ...ve Vacuum Bottles 5 Install a new bottle by tilting an insulator forward and threading the bottle onto the stud The threads must align to prevent cross threading Thread the bottle down leaving a gap of approximately 4 82 mm 0 25 mm 0 190 in 0 01 in between the top of the bottle and the bottom surface of the line terminal Figure 29 Use an appropriate measuring tool to set the gap This gap is precis...

Страница 48: ...n to prevent cross threading Hold the bottle to prevent it from turning while torquing the vacuum bottle mounting bolts Calibrate the Overtravel and Contact Gap 1 Close the contactor by using the TEST control circuit in the starter Insert a feeler gauge of 0 065 in 1 65 mm into the overtravel gap of a bottle assembly Figure 30 2 Rotate the insulator until the gap is correct Repeat for the two rema...

Страница 49: ...r all three bottles must be between 0 180 0 200 in 4 57 5 08 mm If this is the case the replacement procedure is complete If further adjustment is required all three gaps can be adjusted simultaneously by loosening the stop bracket bolts and adjusting the height of the gap adjustment screw at the rear of the contactor Figure 32 To adjust the height of the screw first loosen the locking nut 8 When ...

Страница 50: ...e lower terminal connections at the rear of the contactor and replace eleven M8 bolts to install the fuse mounting mold Lubricate the Contactor Cart 1 Grease the contactor interlock rod using Aeroshell No 7 Figure 33 Figure 33 Lubricate interlock rod Stop Bracket Bolts Gap Adjustment Screw Gap Adjustment Screw Locking Nut Stop Bracket ...

Страница 51: ... Maintenance Chapter 5 2 Grease the front assembly guide rod on both side of the cart using Aeroshell No 7 Figure 34 Figure 34 Lubricate guide rod 3 Grease door to cart interlock sliding bracket Using Aeroshell No 7 Figure 35 Figure 35 Lubricate the sliding bracket ...

Страница 52: ...52 Rockwell Automation Publication 7712 UM001D EN P October 2017 Chapter 5 Maintenance 4 Grease the tulip fingers Using Nye lubricant Nyogel 759G Figure 36 Figure 36 Lubricate the Tulip Fingers ...

Страница 53: ...pter 5 Earthing Switch Maintenance Inspect and Lubricate Earthing Switch Mechanism 1 Inspect the lubrication between the ground stab and the earthing switch blades 2 Apply Nye lubricant Nyogel 759G to the ground stab Figure 37 as needed Figure 37 Lubricate Earthing Switch Mechanism ...

Страница 54: ...lication 7712 UM001D EN P October 2017 Chapter 5 Maintenance 3 Grease Aeroshell No 7 the main shaft mating surface of cam and gear mating surface of shaft and gear housing Figure 38 Figure 38 Lubricate Earthing Switch Mechanism ...

Страница 55: ...d connection 2 If seal is broken apply 11 lb ft 14 5 N m to secure and apply torque seal Figure 39 Ground Connection Inspection Toggle Assembly Inspection 1 Inspect the torque seal of the shoulder bolt for the toggle assembly 2 If seal is broken apply 4 4 lb ft 6 0 N m to secure the shoulder bolt and apply torque seal Figure 40 Toggle Assembly Inspection ...

Страница 56: ...re and secure the auxiliary with the mounting hardware Figure 41 Auxiliary Contacts Replacement Auxiliary Contacts Adjustment The auxiliary is mounted to a slotted L bracket using a M3 5 cheese head screw washer and nut The L bracket with the auxiliary is mounted to the base of the earthing switch using two M6 taptie The switch must be positioned so the roller of the auxiliary sits on top of the a...

Страница 57: ... the adjusted position of auxiliary by tightening the two M6 taptie Figure 42 Auxiliary Contacts Adjustment Earthing Switch Auxiliary Contacts Inspection Operation of electrical auxiliaries must be validated on a yearly basis Refer to the unit electrical drawing to determine the test locations on the terminals located in the low voltage compartment IMPORTANT Auxiliaries must be tested electrically...

Страница 58: ...58 Rockwell Automation Publication 7712 UM001D EN P October 2017 Chapter 5 Maintenance Notes ...

Страница 59: ...are Parts List Description Part Number CPT 300VA 50 60Hz 3300V 110V 220V PN 446670 CPT 300VA 50 60Hz 4160V 115V 230V PN 446676 CPT 300VA 50 60Hz 6600V 6900 V 120V 240V PN 446677 CPT Fuse 6600V 6900V 0 5E 80023 138 04 R CPT Fuse 50 60Hz 2400V 0 75E 80025 239 04 R CPT Fuse 4800V 0 5E 25172 551 02 R Potential Transformer 3300 V 220 230 V 80022 291 02 Potential Transformer 6600 V 220 230 V 80022 291 0...

Страница 60: ...pare Parts List Description Part Number Phase Current Transformers CT Ratio 50 1 80026 696 01 Phase Current Transformers CT Ratio 75 1 80026 696 02 Phase Current Transformers CT Ratio 100 1 PN 466680 Phase Current Transformers CT Ratio 150 1 PN 466681 Phase Current Transformers CT Ratio 200 1 80026 696 05 Phase Current Transformers CT Ratio 250 1 PN 466682 Phase Current Transformers CT Ratio 300 1...

Страница 61: ...oltage switchgear and control gear Part 102 Alternating current disconnectors and earthing switches IEC 62271 200 High voltage switchgear and control gear Part 200 AC metal enclosed switchgear and control gear for rated voltages above 1 kV and up to and including 52 kV Model 7712 Rating Rated Voltage 7 2 kV Rated lightning impulse withstand voltage 60 kV Rated power frequency withstand voltage 20 ...

Страница 62: ...2485R Rockwell Automation HCL Mechanical Operation Tests Earthswitch and starter 50CO IEC 6470 6 101 2 ER 069 2012 Rockwell Automation Interlock 25CO IEC 6470 6 101 3 ER 069 2012 Rockwell Automation Earthswitch Class M1 2000 CO IEC 62271 102 4 106 6 102 ER 110 2011 Rockwell Automation Overload Current Tests 6 kA 1 s IEC 6470 6 102 7 20969 B 26 07 06 2011 Powertech 2 4 kA 30 s Rated making and brea...

Страница 63: ... voltage components To avoid shock hazards complete the Power Lockout procedure on page 27 before servicing the equipment Verify with a hot stick or appropriatevoltage measuring devicethatallcircuitsarevoltage free Failure to do so may result in severe burns injury or death WARNING Usesuitablepersonalprotectiveequipment PPE perlocalcodes or regulations Failure to do so my result in severe burns in...

Страница 64: ...7 Appendix C Troubleshooting Figure 43 Circumvent Earthing Switch to Door Interlock 3 Push the top edge of the interlock mounting bracket downward using a flathead screwdriver Open the door 4 Reverse steps 1 through 2 to reassemble the mounting bracket to the door ...

Страница 65: ...ents To avoid shock hazards complete the Power Lockout procedure on page 27 before servicing the equipment Verify with a hot stick or appropriatevoltagemeasuringdevicethatallcircuitsarevoltagefree Failure to do so may result in severe burns injury or death WARNING Use suitable personal protective equipment PPE per local codes or regulations Failure to do so my result in severe burns injury or deat...

Страница 66: ... a flat head screw driver through the hole on the LV compartment floor and push the lever mounting plate left to release the interlock hook located at the door Figure 45 Figure 45 Circumvent Door to Isolation Shutter 4 Reverse steps 1 through 2 to reassemble the lever arm to roof of the MV compartment ...

Страница 67: ...endix D Mechanical Interlock for 7712 and PowerFlex 7000 Drive Figure 46 PowerFlex drive with bypass using OneGear 7712 controllers Figure 47 Transfer Block Incomer 7791 Bypass 7712 MB Drive Input 7712 D VFD Drive Output 7712 DO Output Cables 7791 F KC KC KC KC KC KB KA ...

Страница 68: ...2 and PowerFlex 7000 Drive Figure 48 PowerFlex Drive with Two Motor Synchronous Transfer Bypass using OneGear 7712 Controllers Figure 49 Transfer Block Incomer 7791 Bypass M1 7712 MB Bypass M2 7712 D Drive Input 7712 VFD Drive Output 7712 DO Output Cables 7712 MO Output Cables 7712 MO KC KC KC KC KC KB KA ...

Страница 69: ... to operate based on the contactor cart position Key is captive in the lock until the contactor is fully racked out and the key is turned When the key is removed the lock must prevent racking the cart in It must be possible to open the door and remove the cart The existing door to cart interlock prevents racking the cart in when the door is open KC Keys for doors 1 Key in the Drive door Prevent th...

Страница 70: ...Interlock Operation Sequence One Motor Initial Condition All doors closed Bypass Drive Input Drive Output contactors in open and the cart withdrawn Bypass earth switch closed KC and KD keys in earth switch KA key in the Drive Input cabinet in transfer block KB key in Drive Output cabinet in transfer block KC keys 4 in transfer block one in earth switch in Bypass cabinet To Run Drive Open earth swi...

Страница 71: ...e with Drive Input contactor closed and Drive Output contactor open To open Drive for Service Open Drive Input contactor withdraw cart Lock open remove KA and KB keys and place them in transfer block Remove KC keys use to open doors To open Output Cabinet Open Bypass contactor and withdraw cart Close earth switch Lock closed remove KD key Put KD and KC keys in door to open Interlock Operation Sequ...

Страница 72: ...72 Rockwell Automation Publication 7712 UM001D EN P October 2017 Appendix D Mechanical Interlock for 7712 and PowerFlex 7000 Drive Notes ...

Страница 73: ......

Страница 74: ...e Direct Dial Code for your product Use the code to route your call directly to a technical support engineer http www rockwellautomation com global support direct dial page Literature Library Installation Instructions Manuals Brochures and Technical Data http www rockwellautomation com global literature library overview page Product Compatibility and Download Center PCDC Get help determining how p...

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